The Real Cost of Ballast Failure in Commercial Lighting Systems
Fluorescent lighting systems rely on ballasts as an intermediary component between the power source and the lamp. While ballasts are often treated as a fixed part of the lighting infrastructure, they are one of the most common failure points in legacy systems.
As facilities transition to LED tubes, the choice between retaining the ballast (Type A) or bypassing it entirely (Type B) has a direct and measurable impact on maintenance labor, downtime, and long-term operating cost.
How Ballast Failures Drive Maintenance Costs
Ballasts operate under continuous thermal and electrical stress. In commercial and industrial environments, elevated ambient temperatures and extended operating hours accelerate ballast degradation.
- Typical electronic ballast life ranges from 3 to 7 years
- Failure rates increase sharply after year five
- One failed ballast disables one or more lamps
Each ballast failure triggers a service event that goes far beyond the cost of the replacement component.
Understanding Type A vs. Type B LED Tube Configurations
| Tube Type | Electrical Path | Ballast Dependency | Primary Risk Factor |
|---|---|---|---|
| Type A | Line → Ballast → LED tube | Required | Ballast failure disables lamp |
| Type B | Line voltage → LED tube | Eliminated | Improper wiring during retrofit |
Type A tubes simplify initial installation but preserve the most failure-prone component in the system.
Labor Impact of Ballast-Related Service Events
Ballast-related service calls consume significantly more labor than lamp replacements.
| Service Event | Average Labor Time | Skill Level Required |
|---|---|---|
| Lamp replacement | 5–10 minutes | Maintenance staff |
| Ballast replacement | 30–60 minutes | Licensed electrician |
| Fixture troubleshooting | 45–90 minutes | Electrician + lift access |
In facilities with hundreds or thousands of fixtures, these time differences compound quickly.
Three-Year Maintenance Cost Comparison
| Cost Category (Per 100 Fixtures) | Type A (Ballast Retained) | Type B (Ballast Bypass) |
|---|---|---|
| Ballast replacements | 15–25 events | 0 |
| Labor hours (maintenance) | 60–100 hours | 20–30 hours |
| Lift or access equipment | Recurring | Minimal |
| Total labor cost impact | Baseline | ≈30% reduction |
The elimination of ballast-related failures is the primary driver behind the documented labor savings.
Secondary Costs Often Overlooked in Ballast Failures
- Production interruptions in active spaces
- Repeated lift deployment and safety setup
- Inconsistent light levels during partial failures
- Inventory stocking of multiple ballast SKUs
These indirect costs rarely appear in energy audits but materially affect operating budgets.
When Type B Ballast Bypass Delivers the Strongest ROI
| Facility Condition | Recommended Tube Type | Reason |
|---|---|---|
| High operating hours (12+ hrs/day) | Type B | Ballast failure risk accelerates with runtime |
| Limited maintenance staff | Type B | Fewer electrical service events |
| High-bay or lift-access fixtures | Type B | Reduces repeat lift deployment |
| Short-term occupancy or leased space | Type A | Lower upfront retrofit labor |
Related LED Tube and Retrofit Categories
Ballast bypass retrofits eliminate a major failure point in legacy lighting systems. Over a three-year operating window, the reduction in service calls, labor hours, and downtime consistently delivers measurable maintenance savings.
Frequently Asked Questions
How has the 179D tax deduction changed for 2026?
The 179D deduction is no longer a one-size-fits-all flat rate. Under the current framework, the deduction follows a sliding scale based on the percentage of energy savings achieved beyond the ASHRAE 90.1 baseline. Furthermore, there is a significant Bonus Deduction available—up to five times the base amount—if the project meets specific prevailing wage and apprenticeship requirements during installation.
What is Lighting Power Density (LPD) and why is it the key metric?
LPD is the total wattage of all lighting fixtures divided by the total square footage of the building ($Watts/ft^2$). To qualify for 179D, your new LED system must reduce the LPD by at least 25% compared to the ASHRAE baseline. High-efficacy LEDs combined with Power-Tuning (Selectable Wattage) fixtures are often used to dial in the exact LPD needed to hit the maximum tax threshold without over-lighting the space.
Do I need advanced controls to qualify for the full deduction?
While you can qualify with fixture upgrades alone, integrating Mandatory Lighting Controls (such as daylight harvesting and occupancy sensing) significantly boosts your modeled energy savings. Because 179D is based on whole-building performance modeling, the logical energy savings provided by controls often push a project from a partial deduction into the highest available tier.
What is the Designer Allocation and how does it work for public buildings?
Since government entities (schools, municipal offices, etc.) do not pay taxes, they cannot use the 179D deduction. However, the law allows these entities to allocate the deduction to the primary designer of the lighting system. This provides a massive financial incentive for engineering and contracting firms to propose high-efficiency LED solutions for public infrastructure projects.
How do I document a lighting-only retrofit for the IRS?
You cannot simply submit a hardware invoice. The IRS requires a Certification Study performed by an independent third party (typically a licensed engineer or contractor) using IRS-approved energy modeling software. This study must prove that the installed lighting system meets the required energy reduction targets and complies with the latest ASHRAE standards.
Can I combine 179D with utility rebates?
Yes. 179D is a federal tax deduction, whereas utility rebates are usually provided by local power companies. In many cases, a commercial LED upgrade can be triple-stacked:
- Utility Rebates: Instant or mail-in cash back for DLC-listed fixtures.
- EPAct 179D: Immediate tax deduction based on square footage.
- Operational Savings: 50–70% reduction in monthly energy bills.
Brandon Waldrop
As the lead technical specialist for our commercial lighting technical operations, Brandon Waldrop brings over 20 years of industry experience in product specification, outside sales, and industrial lighting applications.
His career began in physical lighting showrooms, where he focused on hands-on product performance and technical support. He later transitioned into commercial outside sales, working directly with architects, electrical contractors, and facility managers to translate complex lighting requirements into energy-efficient, code-compliant solutions.
Today, Brandon applies that industry experience to architect high-performance digital catalogs and technical content systems, helping commercial partners streamline the specification process and deploy lighting solutions with total technical confidence.